Service Manual

For the
HM40B and HM47B Rider
Sweeper

For:
Training
Troubleshooting
Adjustments
j

Rev 08/2016
Contents

1 WORKING PRINCIPLE OF THE KS40/47R 3

2 TECHNICAL DATA 4
3 CYLINDRICAL BROOM AND SIDE BROOM 5
3.1 Cylindrical Broom 5
3.2 Main Broom Adjustment 6
3.3 Check and Adjust Sealing Strips 7
3.4 Side Brush Adjustment 8
4 FRONT DRIVE MOTOR ASSEMBLY- BEARING ADUSTMENT 9
4.1 Removing Drive Motor Assembly 10
42
4.2 Replacing the Drive Tire 11
5 LDS (LOW BATTERY DISCHARGE) 15
5.1 Programming the LDS 16
6 DRIVE SYSTEM OVERVIEW 17
61D
6.1 Drive
i C Controller
t ll E Error C
Codes
d 18
6.2 Programming The Drive Controller 19
6.3 Calibrating The Drive Potentiometer 22
6.4 Drive Pedal Adjustment 25
6.5 Drive Motor Specifications 26
7 WIRING DIAGRAM VERSION 1 27
2
8 WIRING DIAGRAM VERSION 2 (With New LDS) 32
1. WORKING PRINCIPLE

The side brush wipes the dirt

at borders and edges into the
collecting track of the wide
y
cylindrical broom.
This broom transports the
debris overhead and into the
dirt hopper. The fine dust
raised during this operation is
evacuated to the suspended
filter by the suction fan where
the dust is separated. The air
returned into the environment
is clean.

3
2. Technical Data

Vehicle dimensions and weights HM40B/HM47B

Length with side brush Mm 1520
Width with 1 side brush Mm 1120
Height above steering wheel Mm 1340
Empty weight – without batteries Kg
Empty weight – serviceable Kg

Driving and sweeping performance

Forward/reverse speed km/h 6.0 / 4.0
S
Sweeping
i speed d k /h
km/h up to
t 6.0
60
Sweeping track with/w/o 1 / with 2 side brushes Mm 700 / 970 / 1240
Theoretical surface performance with 2 side brushes m2/h up to 7450
Theoretical surface performance without side brush m2/h up to 4200
Gradability (for 1 min. max.) % up to 12
Tires
Tire size (serial) front / rear 4.00 – 4/6 Pr Pneumatic tires
Inflation pressure Bar/PSI 6/87

Cylindrical broom
Diameter/ length mm 345 / 700
Diameter (min. due to wearing) mm approx. 290
Speed rpm 530 ± 20
Sweeping track adjustment mm 50 + 10
Bristling PA

Side brushes
Diameter mm 460
Speed rpm approx. 90
Bristling PA

4
3.1 Cylindrical Broom
• Replacing the Cylindrical Broom
• Mount:
• Lower broom
• Remove plastic side cover
• Loosen star-shaped knob (2) and remove left broom arm
• Open both handles and remove lateral plate
• Remove broom by pulling
• Dismount:
• Proceed in inverse order
• Note: Twist broom while inserting until it distinctly catches on the notch.

Star Knob
Broom Arm

Side Cover
Broom Arm

Handles Lateral Plate 5

 3.2 Main Broom Adjustment
• Check Sweeping Track
• Park machine on level concrete or asphalt surface.
• (check inflation pressure of pneumatic tyres and adjust pressure if required)
• Turn on cylinder broom and let it run dry for a short time.
• Lift broom
b andd tturn off,
ff fforward
d th
the machine
hi a bit and d measure sweeping
i ttrack
k width.
idth
• With the correct broom adjustment the parallel sweeping marks have to appear on the floor (sweeping track)
• The sweeping track width should be for the HM40R and HM47R (KS40R- KS47R) 2 Inches ± .2 inches (50 ± 5mm).
• Note: Exceeding the specified sweeping track parameter has a negative effect on the service life of the cylindrical broom.
• The sweeping track reduced as the broom diameter reduces due to wearing of the bristles.
• Adjust parallelism
• Loosen left bearing shell of the torsion shaft
• Adjust parallelism at the stop screw
• Bearing shell
• Torsion shaft
• Stop screw
Sweeping Track Adjustment
• The sweeping track is adjusted after loosening of the handle and turning the star-shaped knob in the engine compartment.
Adjust parallelism
Bearing shell

•Loosen left bearing shell of the torsion 
shaft Torsion shaft

•Adjust parallelism at the stop screw
Stop screw

6
3.3 Sealing Strips

• Check and Adjust Sealing Strips at the Broom Compartment

• In order to assure good function of the sweeper, a perfect condition and correct adjustment of the
sealingg strips
p of the broom compartment
p are required,
q , especially
p y in order to attain the p
prescribed low
pressure (≥ 9mm water column) in the broom compartment, a clean sweeping result and the less
possible wear of the sealing strips.
•
• Proceed to adjustment of the sealing strips at the bottom of the broom compartment on level ground only.
• Th llateral
The t l andd rear sealing
li strips
t i are adjustable
dj t bl iin oblong
bl h
holes,
l th
the ffrontt sealing
li strip
ti bby controlling
t lli
mechanism.
•
• Check the inflation pressure of pneumatic tyres and modify pressure if required.
•
• The sealing strip at the front folding apron has to be lightly inclined backwards and stand on the floor.
•
• Ground clearance of the left- and right-hand sealing strips is 5/64” (2mm)
•
• Ground clearance of the rear sealing strip is approx. = .20” (5mm)
• Note: Replace defective sealing strips immediately

7
3.4 Side Brush Adjustment

Adjust inclination of the side brush such that approx. 2/3 of the brush perimeter has contact with the floor.
For right-hand side brush this ground contact is recommended between 11 and 3 o’clock seen in direction of travel.
For left-hand side brush this ground contact is recommended between 9 and 1 o’clock seen in direction of travel.

•Adjust inclination after loosening the gear holder and by displacing in the oblong holes.
•Adjust height of the lifted side brush at the Bowden cable such that the alignment of the top edges of the belt pulleys is
approx. 10° less than vertical axis. Then the distance between the top side of the V-belt and the fairing holder is about
15mm.
•Tension
e s o ofo tthe
e V-belt
be t iss not
ot adjustable
adjustab e but g
given
e by e
elastic
ast c force.
o ce

Height adjustment

Angle adjustment

Adjustment of pivoting angle (displace in  Screw should axially align with the outer

the oblong hole) border of the frame
8
4. Front Wheel Drive
Bearing Plate Adjustment

Manufactured before 11-2011

Bottom nut tightened with
60 Nm and
simultaneous pivoting of
the wheel

Bottom
otto nut
ut loosened
oose ed

Wheel pivoted by a half

turn

Bottom nut tightened with

30 Nm

Top nut tightened with 120

Nm while bottom
nut position towards the
wheel position is
maintained.
Direction of travel

9
4.1 Removing The Drive Motor

The drive motor can be

removed from the machine by y
doing the following: Motor Leads
1. Disconnect the batteries
2. Jack up the front of the
machine.
3 Disconnect the motor
3.
leads.
4. Remove the four bolts #
21& 29.

10
4.2 Replacing Drive Tire

Steps to be executed for wheel changing

3.
1.

Remove holder between

Dismount drive unit at the
the plate and the brush
separation point between the
flange
wheel support plates

4.
2.

Remove the lateral

Loosen fixing screws of plate sealing plug
and holder

11
4.2 Replacing Drive Tire

5
5. 7
7.

Pull brush flange off Loosen the 

the motor axle 8 wheel bolts

6.
8.

R
Remove brush flange
b h fl Pull off the tire

12
4.2 Replacing Drive Tire

11.
9.

Tighten wheel bolts

Check condition and
crosswise with 16Nm
cleanliness of slip rings

12.
10.

Check carbon brushes

Insert new tyre and tighten for wearing and smooth
wheel bolts crosswise and running in the brush
hand-tight holder

13
4.2 Replacing Drive Tire

15.
13
13.

Insert sealing plug

Place brush flange and into borehole
drive in straight onto the
motor shaft

14. 16.

Screw fastening plate

Then maintenance is 
completed.
completed

Drive unit may be 
mounted to the machine.

14
5. LDS (New Style used after 11-2011)

The LDS controller board has dip switches for setting

the machine to the correct batteryy type
yp such as Wet,
Gel and AGM battery types.
This is required for maximum run time and battery life.

pS
Dip Switches
c es

15
5.1 Programming the LDS
(Signal Transmitter)

Note: Use the “Crown With Offset” for Crown wet

batteries for maximum run time. 16
6. Drive System Overview

17
6.1 Drive Controller Error Codes

18
6.2 Programming The Drive Controller

• Note: When replacing the controller: May require re-calibrating the potentiometer.
• Note: Only trained and authorized Minuteman service technicians are admitted to adjust the
programming the controller.
• Incorrect setting may cause defects of the controller and important malfunctions leading to
uncontrollable riding behaviour of the machine.

• General Description
p of Keys
y

• Three keys are located below the 7-segment LED display. Start programming by pressing the “MODE” key and the
first parameter “F0” appears. Use the “UP” key to step forward to the next parameter (F1, F2 ...) and the “Down”
key to step back. After having attained the desired parameter, select it by pressing the “Mode” key. The parameter
appears
pp in the display.
p y
• If the programming mode has not yet been invoked before pressing the “UP” or “Down” key, display directly
changes to the password level and shows “F00” or “100” while the left cipher flashes.

19
6.2 Programming The Drive Controller

• Enter Password
(Password for potentiometer setting only)

• Use the “UP” and “Down” keys to select the first and flashing number of the three-digit password
and acknowledge by pressing the “Mode” key. Then, enter and acknowledge the next flashing
central cipher alike
alike.
• Upon entering and acknowledging the last, right-hand cipher and in total, the correct password,
display changes to the last parameter or to “F0”
• If entering of one of the three ciphers is incorrect, complete the procedure until after entering if the
last cipher and acknowledgement by “MODE”MODE the display shows “Err”Err briefly.
briefly Then repeat the
complete entering procedure.

• Modify Parameter
In some cases, the 5-pin
p plug
p g of the K3 relay
y in the machine has to be disconnected
before programming the controller.

After correct entering of password, the parameter “F..” selected before appears in the display.
Invoke the numeric value of the parameter by pressing the “MODE” key.
Modify this numeric value of the selected parameter by the “UP/“DOWN”
UP/ DOWN keys.
keys
Acknowledge modification by pressing the “MODE” key.
Then the selected parameter “F..“ is displayed.
20
6.2 Programming The Drive Controller

• Modify Parameter
In some cases, the 5-pin
5 pin plug of the K3 relay in the machine has to be disconnected
before programming the controller.

After correct entering of password, the parameter “F..” selected before appears in the display.
Invoke the numeric value of the parameter by pressing the “MODE” key.
M dif thi
Modify this numeric
i value
l off th
the selected
l t d parameter
t b by th
the “UP/“DOWN” keys.
k
Acknowledge modification by pressing the “MODE” key.
Then the selected parameter “F..“ is displayed.

• It is possible to quit the parameter mode immediately by simultaneous pressing the “MODE” and
“UP” keys.
• The mode is automatically quit after 20 seconds without actuation of key
key. The controller then
attains its operating mode.
• Viewing parameters is possible without entering the password while modification of parameters
always requires entering of password.

21
6.3 Calibrate Drive Potentiometer

When replacing the controller or the drive potentiometer, the controller has to be adapted to the
potentiometer.
1.
1 P
Press “MODE” key
k and d select
l t parametert “F20” using
i ththe “UP” key,
k acknowledge
k l d with
ith “MODE” kkey.
2. Set numeric value of “F20” to “1” using the “UP” key. (Caution: if the programming level has not
yet been invoked, password level is displayed)
3. Enter password and acknowledge with “Mode” key.
4
4. R
Re-select
l t parameter
t “F20” with
ith “UP”/“DOWN” kkeys and d acknowledge
k l d with ith “MODE” kkey.
Set numeric value of “F20” to “1” using the “UP” key and acknowledge.
5. Select parameter “F10” with “DOWN” key and acknowledge with “MODE” key
6. The display then shows the “0” value. If not, use the “UP”/”DOWN” keys to set it to “0” and
acknowledge
k l d with
ith “MODE”
“MODE”.
7. The display then shows “F10” again.
8. While the displays shows “F10“, press the “UP” and “DOWN” keys simultaneously for some seconds
until the display changes.

The left bottom LED segment then shows a “-“ (minus sign) while the
right-hand LED segment displays a potentiometer voltage parameter
between “0” and “5”.
Acknowledge this value with “MODE”
MODE key while the drive pedal is in
neutral position.
22
6.3 Calibrate Drive Potentiometer

9. Display changes. The top left LED segment shows a “-“ (minus sign) while the right-hand LED
segment displays a potentiometer voltage parameter between “0” and “5”.

(example)

10. Actuate drive pedal in forward direction until stop. Then, a value between “10…30” shall appear on the
display. If drive pedal is actuated to maximum, acknowledge with “MODE” key.

11. Display automatically changes to “F0” parameter. The potentiometer is read in.
12. Programming mode is automatically quit after 20 seconds or can be left immediately by simultaneous pressing
the “UP” and “MODE” keys.
13. Re-plug 5-pin plug to K3 relay.
14. Switch machine off and on again, check function of travel drive direction and speed.
23
 6.4 Drive Pedal Adjustment

Potentiometer Gap
For. Switch

Rev. Switch

The potentiometer should be

adjusted so that there is 1
1-2mm
2mm
gap before it is activated.
24
6.5 Drive Motor Specifications

Drive Motor
Blocking Current = Desired 90 ± 5 amps

Normal Current
Forward Current = Desired 17 ± 3 amps
Reverse Current = Desired 12 ± 2 amps

Main Brush Motor

Normal Current = Desired 37 Amps
(Main and side broom motors turned on)

25
7. Belt Locations and Part Numbers

1A. Part # 01131280 Before 3-2005 (V Belt)

1B. Part # 16422313 After 3-2005 (Multi-V Belt)
2. Part # 01131300 Belt
3
3. Part # 01130980 Belt V Belt Multi-V
Multi V Belt
4. Part # 01130710 Right Side Broom Belt Ref . 1A Ref. 1B
5. Part # 01134320 Left Side Broom Belt
26
8. Wiring Diagrams Old Style

• Wiring diagram for models manufactured before

11-2011 are following.

27
Klemmplan
Circuit diagram First Version
Hako Jonas 900 E

Gültig ab: Mai 2004

Valid from: May 2004

Curr. Curr.
Ref. Designation path Ref. Designation path
A1 Control unit /1.8
F1 63A fuse, control unit power module /1.8
F2 20A pre-fuse U switched 1 and 2 /1.15
F3 10A fuse control unit controlling /1.25
F4 5A fuse control panel indicators, shaking /2.24
F5 Fuse reserve /2.17
F6 5A fuse LDS indication /2.14
F7 5A fuse LDS /2.12
F11 30A fuse shaking motor /2.26
F12 60A fuse main motor /2.4
G1 24V battery /1.2
H1 Parking brake pilot lamp (prepared, not fitted) /2.22
H2 Pilot lamp LDS battery okay /2.14
H3 Pilot lamp control unit malfunction /1.12
(prepared, not fitted)
H4 Pilot lamp LDS battery discharged /2.15
H6 Buzzer (prepared, not fitted) /1.24
K1 Relay Multimode /2.11
K2 Relay main motor /2.7
K3 Relay /1.22
K5 Relay /2.24
K5 Impulse relay shaking (option) /2.20
M1 Drive motor /1.5
M1.S1 Thermal contactor drive motor /1.6
M2 Main motor /2.4
M2.S1 Thermal contactor main motor /2.7
M3 Shaking motor /2.25
P1 Hourmeter /2.19
R1 Drive rheostat /1.18
R2 7kS resistor /2.14
S1 Key switch /1.15
S2 Micro-switch reverse ride /1.18
S3 Micro-switch forward ride /1.16
S5 Seat switch /1.20
S6 Micro-switch main motor /2.7
S7 Service/parking brake switch /2.22
(optional fitting possible)
S10 Micro-switch shaking /2.24
Z1 LDS /2.12
1st Ver
1st Ver.
1st Version
9. Wiring Diagrams New Style

• Wiring diagram for models manufactured after

11-2011 are following.

28
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